Repair system and method

ABSTRACT

A method of repairing a flexible pipe within a carrier pipe. The method then increases a first area of a first hole in the carrier pipe. The method then bends a first layer of the flexible pipe around a second hole in the first layer. The method then patches a third hole in a second layer of the flexible pipe.

BACKGROUND

This section is intended to introduce the reader to various aspects ofart that may be related to various aspects of the present disclosure,which are described below. This discussion is believed to be helpful inproviding the reader with background information to facilitate a betterunderstanding of the various aspects of the present disclosure.Accordingly, it should be understood that these statements are to beread in this light, and not as admissions of prior art.

In some places, pipeline operators could experience fuel theft throughillegal tapping of their pipelines. Thieves may steal the fuel bydigging to reach a buried pipeline and then drilling a hole in the pipe.The release of fuel through the hole may be collected with hoses andbuckets for use by the thieves or sold on the black market. Theseillegal taps result in fuel loss and spillage that damages theenvironment, and may affect the structural integrity of the pipelines.

SUMMARY

This summary is provided to introduce a selection of concepts that arefurther described below in the detailed description. This summary is notintended to identify key or essential features of the claimed subjectmatter, nor is it intended to be used as an aid in limiting the scope ofthe claimed subject matter.

Instead of or in addition to digging up a pipeline or digging newtrenches to install new pipeline, flexible pipe may be installed intoexisting pipeline infrastructure. Indeed, flexible pipe is durable andoperational in harsh operating conditions and can accommodate highpressures and temperatures. In the event that even the flexible pipe istapped or damaged, however, holes in the flexible pipe afterinstallation inside other pipeline infrastructure may be repaired.

In one example, the disclosure describes a method of repairing aflexible pipe within a carrier pipe. The method then increases a firstarea of a first hole in the carrier pipe. The method then bends a firstlayer of the flexible pipe around a second hole in the first layer. Themethod then patches a third hole in a second layer of the flexible pipe.

In another example, the disclosure describes a pipe system that includesa carrier pipe and a flexible pipe within the carrier pipe. The flexiblepipe includes a first layer of material and a second layer of materialsurrounding the first layer of material. The second layer of materialincludes metal. A seal system seals a first hole in the carrier pipe.The seal system includes a seal body that couples to the carrier pipe.The seal body defines a first port and a second port. The first portreceives a material that fills an annulus formed between the carrierpipe and the flexible pipe. The second port releases gas between theflexible pipe and the carrier pipe.

In another example, the disclosure describes a seal system includes aseal body that couples to a carrier pipe. The seal body defines a firstport and a second port. The first port receives a material that fills anannulus formed between the carrier pipe and a flexible pipe. The secondport releases gas between the flexible pipe and the carrier pipe as theannulus fills with the material.

Other aspects and advantages of the claimed subject matter will beapparent from the following description and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective cross-sectional view of a flexible pipeinstalled within a carrier pipe, according to embodiments of the presentdisclosure.

FIG. 2 is a cross-sectional side view of a flexible pipe within acarrier pipe with a hole drilled through the carrier pipe and theflexible pipe, according to embodiments of the present disclosure.

FIG. 3 is a cross-sectional side view of the flexible pipe within thecarrier pipe seen in FIG. 1 after widening the hole in the carrier pipe,according to embodiments of the present disclosure.

FIG. 4 is a cross-sectional side view of the flexible pipe within thecarrier pipe seen in FIG. 3 with the metal layer of the flexible pipepulled or bent away from the hole, according to embodiments of thepresent disclosure.

FIG. 5 is a cross-sectional side view of the flexible pipe within thecarrier pipe seen in FIG. 4 with a plug installed in the hole of theinnermost layer of the flexible pipe, according to embodiments of thepresent disclosure.

FIG. 6 is a cross-sectional side view of the flexible pipe within thecarrier pipe seen in FIG. 4 with an electrofusion or welded patchcovering the hole of the innermost layer of the flexible pipe, accordingto embodiments of the present disclosure.

FIG. 7 is a cross-sectional side view of the flexible pipe within thecarrier pipe seen in FIG. 4 with a gasket over the hole of the innermostlayer of the flexible pipe and secured in place with a band clamp,according to embodiments of the present disclosure.

FIG. 8 is a cross-sectional side view of the flexible pipe within thecarrier pipe seen in FIG. 5 with seals placed around the flexible pipeupstream and downstream of the hole, according to embodiments of thepresent disclosure.

FIG. 9 is a cross-sectional side view of the flexible pipe within thecarrier pipe seen in FIG. 8 with seals placed around the flexible pipeupstream and downstream of the hole and a seal system coupled to anexterior surface of the carrier pipe, according to embodiments of thepresent disclosure.

FIG. 10 is a cross-sectional side view of the flexible pipe within thecarrier pipe seen in FIG. 9 with the annular space between the flexiblepipe and the carrier pipe filled with a material, according toembodiments of the present disclosure.

FIG. 11 is a cross-sectional side view of a flexible pipe within acarrier pipe seen in FIG. 5 with a seal system within an annular spacebetween the flexible pipe and the carrier pipe, according to embodimentsof the present disclosure.

FIG. 12 is a cross-sectional side view of the flexible pipe within thecarrier pipe seen in FIG. 11 with the annular space between the flexiblepipe and the carrier pipe filled with a material, according toembodiments of the present disclosure.

FIG. 13 is a cross-sectional side view of the flexible pipe within thecarrier pipe seen in FIG. 5 with a leak detection pipe in the annularspace between the flexible pipe and the carrier pipe, according toembodiments of the present disclosure.

FIG. 14 is a cross-sectional side view of the flexible pipe within thecarrier pipe seen in FIG. 13 with a leak detection pipe in the annularspace between the flexible pipe and the carrier pipe and the annularspace filled with a material, according to embodiments of the presentdisclosure.

FIG. 15 is a flowchart of a method of repairing a hole in a flexiblepipe, according to embodiments of the present disclosure.

DETAILED DESCRIPTION

Certain embodiments commensurate in scope with the present disclosureare summarized below. These embodiments are not intended to limit thescope of the disclosure, but rather these embodiments are intended onlyto provide a brief summary of certain disclosed embodiments. Indeed, thepresent disclosure may encompass a variety of forms that may be similarto or different from the embodiments set forth below.

As used herein, the term “coupled” or “coupled to” may indicateestablishing either a direct or indirect connection, and is not limitedto either unless expressly referenced as such. The term “set” may referto one or more items. Wherever possible, like or identical referencenumerals are used in the figures to identify common or the sameelements. The figures are not necessarily to scale and certain featuresand certain views of the figures may be shown exaggerated in scale forpurposes of clarification.

Furthermore, when introducing elements of various embodiments of thepresent disclosure, the articles “a,” “an,” and “the” are intended tomean that there are one or more of the elements. The terms “comprising,”“including,” and “having” are intended to be inclusive and mean thatthere may be additional elements other than the listed elements.Additionally, it should be understood that references to “oneembodiment” or “an embodiment” of the present disclosure are notintended to be interpreted as excluding the existence of additionalembodiments that also incorporate the recited features. Furthermore, thephrase A “based on” B is intended to mean that A is at least partiallybased on B. Moreover, unless expressly stated otherwise, the term “or”is intended to be inclusive (e.g., logical OR) and not exclusive (e.g.,logical XOR). In other words, the phrase A “or” B is intended to mean A,B, or both A and B.

As explained above, pipeline operators may experience fuel theft throughillegal tapping of their pipelines. These illegal taps result in fuelloss, spillage that damages the environment, and may affect thestructural integrity of the pipelines. However, instead of digging upthe existing pipeline or digging new trenches to install new pipeline,flexible pipe is installed inside the existing pipeline. The existingpipeline then becomes a carrier pipe that provides a conduit for therapid deployment of flexible pipe. However, the ability to seal holes inthe flexible pipe presents a significant challenge. Specifically, thestructure of the flexible pipe may limit the type of repairs that may beperformed. As will be explained below, flexible pipe may consist ofmultiple layers of polymers (e.g., high density polyethylene) thatencase one or more layers of metal strips (e.g., steel). Accordingly,patching an illegal tap presents the challenge of sealing a hole throughmultiple layers of different materials. In contrast, existing steelpipelines may be repaired by simply welding a plate to the steel pipeover the hole. The disclosure below describes a repair system and methodthat enables repair of flexible pipe, such as when the flexible pipe isdisposed within an existing carrier pipe. And as will be explained ingreater detail, the repair method and repair system use the uniquearrangement of flexible pipe within a carrier pipe to enable sealing andrepair of the flexible pipe.

FIG. 1 is a perspective cross-sectional view of a flexible pipe 10(e.g., conduit) installed within a carrier pipe 12 (e.g., conduit) toform a pipeline infrastructure or pipe system 14. The carrier pipe 12defines a bore 16 that receives the flexible pipe 10 duringinstallation. Placing flexible pipe 10 within an existing pipe may savetime and money by reducing and/or eliminating the construction oftrenches and/or other infrastructure for laying flexible pipe. In somesituations, the carrier pipe 12 may already be buried below the surface.However, fuel thieves may still drill holes 18 in the carrier pipe 12 inorder to steal fuel. Once thieves realize that the carrier pipe 12 isdry, they may drill into the flexible pipe 10 to access the fuel.Drilling through the flexible pipe 10 involves drilling through multiplelayers of material. For example, the flexible pipe 10 may include afirst or inner layer 20 that may be made from a thermoplastic (e.g.,high density polyethylene (HDPE)). The inner layer 20 defines a bore 22that carries a fluid (e.g., fuel). Surrounding the inner layer 20 is asecond or middle layer 24 that may be made from a metal(s) (e.g., steelstrips) that provides strength to the flexible pipe 10. And surroundingthe middle layer 24 may be a third or outer layer 26 made from athermoplastic (e.g., HDPE). The inner layer 20 and the outer layer 26may protect the middle layer from fluids within the bore 22 as well asfrom fluids and substances outside of the flexible pipe 10. For example,the inner layer 20 and the outer layer 26 may protect the middle layer24 from corrosion.

It should be understood that flexible pipe 10 is a tube that conveys ortransfers any water, gas, oil, or any type of suitable fluid. Theflexible pipe 10 may be made of any type of materials includingplastics, metals, composites (e.g., fiber-reinforced composites), and/orother suitable materials. The flexible pipe 10 may include Bonded orUnbonded Flexible Pipe, Flexible Composite Pipe (FCP), ThermoplasticComposite Pipe (TCP) or Reinforced Thermoplastic Pipe (RTP). FCP or RTPpipe may itself be generally composed of several layers. In one or moreembodiments, a flexible pipe may include a thermoplastic liner orinternal pressure sheath having a reinforcement layer and athermoplastic outer cover layer. In one or more embodiments, thethermoplastic may be high density polyethylene (HDPE). Thus, flexiblepipe may include different layers that may be made of a variety ofmaterials and may also provide corrosion resistance. For example, in oneor more embodiments, pipe used to make up a coil of pipe may have acorrosion protection outer cover layer that is disposed over anotherlayer of steel reinforcement. In this embodiment, helically wound steelstrips may be placed over a liner made of thermoplastic pipe. Flexiblepipe may be designed to handle a variety of pressures. Accordingly,flexible pipe may offer unique features and benefits versus steel/carbonsteel pipe lines in the area of corrosion resistance, flexibility,installation speed and re-usability. Another type of flexible orspoolable pipe is coiled tubing or reeled tubing, which may be made ofsteel and have corrosion protection shield layer.

FIG. 2 is a cross-sectional side view of the flexible pipe 10 within thecarrier pipe 12. The carrier pipe 12 defines an aperture or hole 18 andthe flexible pipe 10 similarly defines holes or holes 40, 42, and 44having a cross-sectional area or diameter 46 within the respectivelayers 20, 24, and 26 (e.g., first layer, second layer, third layer).These holes 18, 40, 42, and 44 may be formed by a thief drilling a holeto access fuel carried in the bore 22 of the flexible pipe 10. After thethief drills the holes 18, 40, 42, and 44 through the carrier pipe 12and the flexible pipe 10, the holes 18, 40, 42, and 44 may have asimilar cross-sectional area or diameter. As will be explained below,the method of repairing the flexible pipe 10 involves changing theseinitial diameters.

FIG. 3 is a cross-sectional side view of the flexible pipe 10 within thecarrier pipe 12 seen in FIG. 1. The method of repairing the flexiblepipe 10 may begin with increasing a cross-sectional area or diameter 60of the hole 18 to form an access port or window. Increasing the size ofhole 18 facilitates access to and insertion of tools or equipment intothe bore 16 of the carrier pipe 12. The size of the hole 18 may beincreased by cutting the carrier pipe 12 using cold cutting or hotcutting techniques. In some situations, it may be desirable to cold cutthe carrier pipe 12 when increasing the size of the hole 18 to block orreduce combustion of fuel or fumes within the flexible pipe 10 orcarrier pipe 12. In some embodiments, after increasing the size of thehole 18, the repair method involves increasing a cross-sectional area ordiameter 62 of the hole 44. Clearing away material of the outer layer 26exposes the material (e.g., metal, steel strips) of the middle layer 24surrounding the hole 42.

FIG. 4 is a cross-sectional side view of the flexible pipe 10 within thecarrier pipe 12 seen in FIG. 3. After clearing/removing material fromthe outer layer 26 surrounding the hole 44, the material of the middlelayer 24 may be bent or pulled back. For example, the middle layer 24may be a metal (e.g., steel, steel strips). The bending or pulling ofthe material of the middle layer 24 forms protrusions 70 that projectaway from the outer layer 26 and increase the size of the hole 42. Theseprotrusions 70 may extend a distance 72 (e.g., 0.5-5 inches, 1-3 inches,1-2 inches, 0.5 inches) beyond the outermost surface of the outer layer26. As will be explained below, the protrusions 70 may enable theflexible pipe 10 to handle tensile loads while carrying a pressurizedfluid (e.g., fuel).

FIG. 5 is a cross-sectional side view of the flexible pipe 10 within thecarrier pipe 12 seen in FIG. 4. The repair method seen in FIG. 4continues in FIG. 5 by blocking the hole 40. In some embodiments, atapered or threaded pipe plug 80 may be installed to seal the hole 40.The repair method may also include prepping the hole 40 by drilling ortrimming the inner layer 20 around the aperture. For example, drillingor trimming around the hole 40 may size and/or prepare the inner layer20 to receive the pipe plug 80.

FIG. 6 is a cross-sectional side view of the flexible pipe 10 within thecarrier pipe 12 seen in FIG. 4. In some embodiments, the repair methodmay involve electrofusing or welding a patch 90 to seal the hole 40. Insome embodiments, the patch 90 may extend beyond the cross-sectionalarea of the hole 40 where the patch 90 couples to the outer surface 92of the inner layer 20.

FIG. 7 is a cross-sectional side view of the flexible pipe 10 within thecarrier pipe 12 seen in FIG. 4. In some embodiments, the repair methodmay secure a gasket 100 over the hole 40. For example, the gasket 100may be secured in place with a clamp 102. The clamp 102 may be a bandclamp that extends around the flexible pipe 10 to hold the gasket 100 inplace. In some embodiments, in order to place the clamp 102 around theflexible pipe 10, some of the protrusions 70 (e.g., circumferentialprotrusions) may be trimmed or cutoff to facilitate contact between theclamp 102 and the gasket 100. In this way, the clamp 102 may provide thecompressive force for sealing the gasket 100 against the inner layer 20.

FIG. 8 is a cross-sectional side view of the flexible pipe 10 within thecarrier pipe 12 seen in FIG. 5. As will be explained in FIGS. 9 and 10,in order to maintain the seal over the hole 40 as well as to discouragefurther attempts to reopen the hole 40, a material (e.g., cement, epoxy)may be injected into the bore 16 between the flexible pipe 10 and thecarrier pipe 12. To block the material from flowing excessively upstreamand/or downstream from the location of the hole 40, the repair methodincludes placing temporary seals 110 in the bore 16. The seals 110 areplaced upstream and downstream from the hole 40 and circumferentiallyextend about the exterior surface 74 of the outer layer 26 to form aseal between the carrier pipe 12 and flexible pipe 10. For example, theseals 110 may be placed 1-6 inches, 1-12 inches, 1-24 or more bothupstream and downstream from the axis of the hole 40. The seals 110 maybe a rubber seal, a plastic seal, a foam seal, a swellable seal (e.g.,absorbent polymer), among others. The seals 110 in FIG. 8 may be foam orswellable seals that expand to fill the bore 16 between the flexiblepipe 10 and the carrier pipe 12. In some embodiments, apertures 112 maybe made in the carrier pipe 12 to facilitate placement of the temporaryseals 110 in the bore 16. In other embodiments, the seals 110 may beinserted through the hole 18 and positioned with tools.

FIG. 9 is a cross-sectional side view of the flexible pipe 10 within thecarrier pipe 12 seen in FIG. 8. As illustrated, the seals 110 form aseal between the flexible pipe 10 and the carrier pipe 12. For example,foam seals may have expanded and hardened or swellable seals may haveabsorbed a fluid that enabled them to expand and harden. Once the seals110 are in place and have formed a seal between the flexible pipe 10 andthe carrier pipe 12, the repair method continues by coupling a sealsystem 120 over the hole 18 in the carrier pipe 12. The seal system 120includes a seal body 121 that couples to the exterior surface 122 and insome embodiments may wrap around the circumference of the carrier pipe12. In another embodiment, the seal body 121 may be welded to thecarrier pipe 12. In still other embodiments, the seal body 121 may bebolted to the carrier pipe 12 with bolts 124.

The seal body 121 defines a first port 126 and a second port 128. Inoperation, the first port 126 enables material 129 (e.g., cement, epoxy)to be pumped into the annulus 130 formed between the seals 110 andbetween the flexible pipe 10 and the carrier pipe 12. As the annulus 130fills with the material 129, air within the annulus 130 escapes (e.g.,releases) through a valve 132 (e.g., one-way valve, check valve). Thematerial 129 is pumped or injected into the annulus from a materialsource 134 that couples to the first port 126 with a hose 136.

FIG. 10 is a cross-sectional side view of the flexible pipe 10 withinthe carrier pipe 12 seen in FIG. 9 with the annulus 130 filled with thematerial 129. After injection of the material 129 into the annulus 130,the first port 126 may be sealed or closed with a cap 152 to block theescape of the material 129. The material 129 (e.g., cement, epoxy) maythen cure within the annulus 130 providing a protective barrier aroundthe hole 40 in the flexible pipe 10.

As explained above, the repair method involves bending the middle layer24 (e.g., metal layer, metal strips) to form protrusions 70 that projectaway from the outer layer 26 and increase the size of the hole 42. Oncethe material 129 hardens in the annulus 130 and around the protrusions70, the hardened material 129 interacts with the protrusions 70 tosupport tensile loads that act on the flexible pipe 10 in response to apressurized fluid in the bore 22. In other words, the hardened material129 blocks movement of the protrusions 70 in directions 154 and 156 aswell as circumferentially in direction 158 in response to pressureloads. If not countered, excessive pressure loads around the hole 40 mayenable fluid to escape the inner layer 20 of the flexible pipe 10.

FIG. 11 is a cross-sectional side view of the flexible pipe 10 withinthe carrier pipe 12 seen in FIG. 5 with a seal body 168 of a seal system170 positioned within the carrier pipe 12. In operation, the seal system170 enables a material 171 (e.g., epoxy, cement) to be pumped into anannulus 172 while simultaneously forming a seal about the hole 18 in thecarrier pipe 12. The annulus 172 is circumferentially formed between theflexible pipe 10 and the carrier pipe 12 and longitudinally between theseals 174.

The seals 174 block or reduce the flow of the material 171 beyond adesired distance from the hole 40. The seals 174 are placed upstream anddownstream from the hole 40 and circumferentially extend about theexterior surface 74 of the outer layer 26 to form a seal between thecarrier pipe 12 and the flexible pipe 10. The seals 174 may be a rubberseal, a plastic seal, a foam seal, a swellable seal (e.g., absorbentpolymer), among others.

Once the seals 174 are in place and have formed a seal between theflexible pipe 10 and the carrier pipe 12, the repair method continues byinserting the seal body 168 through the hole 18. After insertion, theseal body 168 is reoriented to cover the hole 18. The seal body 168includes a first port 176 and a second port 178. In operation, the firstport 176 enables the material 171 (e.g., cement, epoxy) to be pumpedinto the annulus 172 formed between the seals 174 and between theflexible pipe 10 and the carrier pipe 12. As the annulus 172 fills withthe material 171, air within the annulus 172 is able to escape (e.g.,release) through a valve 180 (e.g., one-way valve, check valve) coupledto the second port 178. The material 171 is pumped or injected into theannulus 172 from a material source 182 that couples to the first port176 with a hose 184.

Prior to injection of the material 171, the seal body 168 is held inplace using arms 186 that are pivotally coupled to the seal body 168with a pivot joint 188. After inserting and orienting the seal body 168,the arms 186 are rotated from an upright position to an angled positionthat contacts the exterior surface 190 of the carrier pipe 12. In thisway, the arms 186 suspend the seal body 168 inside the carrier pipe 12while filling the annulus 172 with the material 171. In someembodiments, the seal body 168 may be suspended and held in place withstraps or chains that couple to anchors on the seal body 168 until thematerial 171 fills the annulus 172 and blocks movement of the seal body168.

FIG. 12 is a cross-sectional side view of the flexible pipe 10 withinthe carrier pipe 12 seen in FIG. 11 with the annulus 172 between theflexible pipe 10 and the carrier pipe 12 filled with the material 171.After injection of the material 171 into the annulus 172, the first port176 may be sealed or closed with a cap 200 to block the escape of thematerial 171. The material 171 (e.g., cement, epoxy) may then curewithin the annulus 172 providing a protective barrier around the hole 40in the flexible pipe 10 as well blocking movement of the seal body 168.

As explained above, the repair method involves bending the middle layer24 (e.g., metal layer, metal strips) to form protrusions 70 that projectaway from the outer layer 26 and increase the size of the hole 42. Oncethe material 171 hardens in the annulus 130 and around the protrusions70, the hardened material 171 interacts with the protrusions 70 tosupport tensile loads that act on the flexible pipe 10 as a pressurizedfluid flows through the bore 22. In other words, the hardened material171 blocks movement of the protrusions 70 in directions 202 and 204 andcircumferentially in direction 206 in response to pressure loading ofthe flexible pipe 10 from pressurized fluid flowing through the bore 22.By constraining movement of the protrusions 70, the material 171 reducesmovement of the middle layer 24 (e.g., metal layer), which in turnblocks or reduces the hole 40 from increasing in size, which couldenable fluid to escape.

FIG. 13 is a cross-sectional side view of the flexible pipe 10 withinthe carrier pipe 12 seen in FIG. 5. As explained above, fuel thieves maytap the carrier pipe 12 and flexible pipe 10 to access fuel carried inthe bore 22. In order to detect these illegal tap(s), pressure sensingdevices monitor the pressure within the bore 16 of the carrier pipe 12.These pressure sensing devices monitor fluctuations in the pressure ofthe bore 16. When a thief drills a hole in the carrier pipe 12, thepressure within the carrier pipe 12 rapidly equalizes with the pressureof the environment surrounding the carrier pipe 12. This change inpressure is detected by pressure sensing devices installed along thecarrier pipe 12 enabling pipeline operators to rapidly detect anddetermine the location of the illegal tap. Unfortunately, if the bore 16is sealed and filled with material (e.g., epoxy, cement) at one or morelocations along the carrier pipe 12 pressure communication isinterrupted. For example, the bore 16 may be sealed and filled from aprevious repair of the flexible pipe 10, the pressure sensing devicesmay not detect additional illegal taps. The repair method may thereforeinclude installing a leak detection pipe(s) 220 (e.g., 1, 2, 3, or more)in the bore 16 of the carrier pipe 12. In operation, the leak detectionpipe 220 enables pressure communication across a repair site. In otherwords, fluid (e.g., air) may flow through the leak detection pipe 220from a point downstream of the repair site to a position upstream fromthe repair site or vice versa enabling the transmission of pressurechanges.

FIG. 14 is a cross-sectional side view of the flexible pipe 10 withinthe carrier pipe 12 seen in FIG. 13 with the leak detection pipe 220extending through an annular space 222 of the repair site 223. Theannular space 222 is formed between the seals 224 and between theflexible pipe 10 and the carrier pipe 12. As illustrated, the leakdetection pipe 220 extends through the seals 224 enabling fluidcommunication between upstream and downstream positions of the seals224. As explained above, the annular space 222 is filled with a material226 (e.g., epoxy, cement) by pumping the material 226 through a sealsystem 228. The material 226 encases and protects the leak detectionpipe 220 through the repair site 223. The seal system 228 includes withseal body 229. The seal body 229 includes a first port 230 and a secondport 232. In operation, the first port 230 enables the material 226(e.g., cement, epoxy) to be pumped into the annular space 222 while alsosealing the hole 18 in the carrier pipe 12. As the annular space 222fills with the material 226, air within the annular space 222 is able toescape (e.g., release) through a valve 234 (e.g., one-way valve, checkvalve) coupled to the second port 232. After filling the annular space222, the first port 230 is closed off with a cap 236. In this way, therepair method enables repair of the hole 40 while also enablinginstallation of a leak detection pipe 220.

FIG. 15 is a flowchart of a method 260 of repairing a hole in a flexiblepipe (e.g., flexible pipe 10). The method 260 may begin by increasing anarea of a hole in a carrier pipe (e.g., carrier pipe 12), step 262.Increasing the area of the hole in the carrier pipe facilitates accessto the flexible pipe. After accessing the flexible pipe, the method 260may bend a first layer (e.g., metal strip layer) of the flexible pipeaway from a hole in the first layer, step 264. The method 260 thenpatches a hole in a second layer (e.g., inner layer 20) of the flexiblepipe, step 266. After patching the hole in the second layer, first andsecond seals (e.g., seals 110) are placed in an annulus or annular spacebetween the flexible pipe and the carrier pipe, step 268. With the sealsin place, the method 260 injects material (e.g., concrete, epoxy) intothe annulus between the seals to form a seal that holds the patch inplace, step 270. The method 260 disclosed herein includes various stepsrepresented by blocks. Although the flowchart illustrates the steps in acertain sequence, it should be understood that the steps may beperformed in any suitable order and certain steps may be carried outsimultaneously, where appropriate. Additionally, steps may be added toor omitted from the method 260. For example, the method 260 may includeadditional steps as described above in the description of FIGS. 2-14.

Technical effects of the invention include the ability to seal holes ina flexible pipe positioned within a carrier pipe.

As used herein, the terms “inner” and “outer”; “up” and “down”; “upper”and “lower”; “upward” and “downward”; “above” and “below”; “inward” and“outward”; and other like terms as used herein refer to relativepositions to one another and are not intended to denote a particulardirection or spatial orientation. The terms “couple,” “coupled,”“connect,” “connection,” “connected,” “in connection with,” and“connecting” refer to “in direct connection with” or “in connection withvia one or more intermediate elements or members.”

The foregoing description, for purpose of explanation, has beendescribed with reference to specific embodiments. However, theillustrative discussions above are not intended to be exhaustive or tolimit the disclosure to the precise forms disclosed. Many modificationsand variations are possible in view of the above teachings. Moreover,the order in which the elements of the methods described herein areillustrated and described may be re-arranged, and/or two or moreelements may occur simultaneously. The embodiments were chosen anddescribed in order to best explain the principals of the disclosure andits practical applications, to thereby enable others skilled in the artto best utilize the disclosure and various embodiments with variousmodifications as are suited to the particular use contemplated.

The techniques presented and claimed herein are referenced and appliedto material objects and concrete examples of a practical nature thatdemonstrably improve the present technical field and, as such, are notabstract, intangible or purely theoretical. Further, if any claimsappended to the end of this specification contain one or more elementsdesignated as “means for [perform]ing [a function] . . . ” or “step for[perform]ing [a function] . . . ”, it is intended that such elements areto be interpreted under 35 U.S.C. 112(f). However, for any claimscontaining elements designated in any other manner, it is intended thatsuch elements are not to be interpreted under 35 U.S.C. 112(f).

What is claimed is:
 1. A method of repairing a flexible pipe that is disposed within a bore of a carrier pipe, comprising: increasing an area of a first hole formed in the carrier pipe, wherein the first hole in the carrier pipe is aligned with a second hole formed in an outer layer of the flexible pipe, a third hole formed in a middle layer of the flexible pipe, and a fourth hole formed in an inner layer of the flexible pipe; bending material around the third hole in the middle layer of the flexible pipe via the first hole in the carrier pipe to increase an area of the third hole and to form one or more protrusions that extend beyond the outer layer of the flexible pipe; and patching the fourth hole in the inner layer of the flexible pipe via the third hole in the middle layer of the flexible pipe.
 2. The method of claim 1, comprising sealing the first hole in the carrier pipe.
 3. The method of claim 2, wherein sealing the first hole in the carrier pipe comprises coupling a seal system to the carrier pipe over the first hole.
 4. The method of claim 1, wherein bending material around the third hole in the middle layer of the flexible pipe comprises bending a portion of a metal strip in the middle layer to form a protrusion that extends beyond the outer layer of the flexible pipe.
 5. The method of claim 1, wherein patching the fourth hole in the inner layer of the flexible pipe comprises: electrofusing the inner layer of the flexible pipe; welding a patch over the fourth hole in the inner layer of the flexible pipe; inserting a plug into the fourth hole in the inner layer of the flexible pipe; placing a gasket over the fourth hole in the inner layer of the flexible pipe and securing a clamp to the flexible pipe over the gasket; or any combination thereof.
 6. The method of claim 1, comprising drilling or trimming material around the fourth hole in the inner layer of the flexible pipe before patching the fourth hole in the inner layer.
 7. The method of claim 1, comprising increasing area of the second hole in the outer layer of the flexible pipe via the first hole in the carrier pipe, wherein bending the material around the third hole in the middle layer of the flexible pipe comprises bending the material around the third hole in the middle layer of the flexible pipe via the second hole in the outer layer of the flexible pipe.
 8. The method of claim 1, wherein increasing area of the first hole in the carrier pipe comprises cold cutting or hot cutting material around the first hole in the carrier pipe.
 9. The method of claim 1, comprising: disposing a first seal within an annular space between the carrier pipe and the outer layer of the flexible pipe upstream of the fourth hole in the inner layer of the flexible pipe; and disposing a second seal within the annular space between the carrier pipe and the outer layer of the flexible pipe downstream of the third hole in the inner layer of the flexible pipe.
 10. The method of claim 9, comprising: injecting another material into the annular space between the outer layer of the flexible pipe and the carrier pipe; and curing the other material within the annular space.
 11. The method of claim 10, wherein injecting the other material into the annular space comprises injecting cement or epoxy into the annular space.
 12. The method of claim 10, comprising placing a leak detection pipe into the annular space before injecting the other material into the annular space to facilitate detecting subsequent hole formation in the carrier pipe.
 13. The method of claim 10, wherein curing the other material within the annular space comprises hardening the other material around the one or more protrusions formed in the middle layer to facilitate supporting tensile loads exerted on the flexible pipe.
 14. The method of claim 9, wherein: disposing the first seal within the annular space comprises inserting a first foam seal or a first swellable seal into the annular space via the first hole in the carrier pipe; and disposing the second seal within the annular space comprises inserting a second foam seal or a second swellable seal into the annular space via the first hole in the carrier pipe.
 15. The method of claim 9, wherein: disposing the first seal within the annular space comprises: forming a first aperture in the carrier pipe upstream of the first hole in the carrier pipe; and inserting the first seal into the annular space via the first aperture in the carrier pipe; and disposing the second seal within the annular space comprises: forming a second aperture in the carrier pipe downstream of the first hole in the carrier pipe; and inserting the second seal into the annular space via the second aperture in the carrier pipe.
 16. A method of repairing a flexible pipe within a carrier pipe, comprising: increasing an area of a first hole in the carrier pipe; bending a first layer of the flexible pipe around a second hole in the first layer; and patching a third hole in a second layer of the flexible pipe.
 17. The method of claim 16, comprising sealing the first hole in the carrier pipe.
 18. The method of claim 16, wherein bending the first layer of the flexible pipe comprises bending portions of metal strips that form the first layer.
 19. The method of claim 16, wherein patching the third hole comprises: electrofusing the second layer; welding a patch over the third hole; inserting a plug into the third hole; placing a gasket over the third hole and coupling a clamp to the flexible pipe over the gasket; or any combination thereof.
 20. The method of claim 16, comprising: inserting a first seal upstream of the third hole and a second seal downstream of the third hole; and injecting a material into an annular space formed between the first seal, the second seal, the flexible pipe, and the carrier pipe. 